First Draft Gypsum Board
First Draft Gypsum Board
APRIL 2022
Project Proposal on Gypsum Powered Manufacturing Project
Contents
1. EXECUTIVE SUMMARY.....................................................................................................5
2. Introduction...........................................................................................................................7
7.1. General.........................................................................................................................24
7.2. Investment cost............................................................................................................24
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Project Proposal on Gypsum Powered Manufacturing Project
9. RISK ANALYSIS..............................................................................................................36
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Project Proposal on Gypsum Powered Manufacturing Project
BASIC INFORMATION
26,373,150 of which:
Land requirement: the total area of land to require for this project is
3500 m2
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Project Proposal on Gypsum Powered Manufacturing Project
1. EXECUTIVE SUMMARY
The total startup capital of the, project is 26,375,110 birr, Out of the total
capital, birr 7,911,945 (30%) is contributed by the promoter; while the
remaining balance of 18,461,205 (70%) is to be financed by local bank loan.
[
The purpose of the loan is to purchase machinery and working capital cost, the
promoter believes the loan has strengthened the relationship between the
investor and the bank, in addition to these loans and advances to various
sectors of the economy on the strength of viability and assessment of
concentration risk will increase the success of the business.
Profitability: The financial analysis of the envisaged project is carried out for
the following ten years. Based on the 10 years financial projections using the
income statement, cash flow statement and financial internal rate of return
(FIRR) and the following results are obtained
Income statement: According to the projected income statement, the
project will generate profit beginning from the first year of operation.
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Project Proposal on Gypsum Powered Manufacturing Project
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Project Proposal on Gypsum Powered Manufacturing Project
2. Introduction
Ethiopia is now becoming more and more investment friendly country. The
Government is creating favorable condition that would highly encourage the
private sector to be engaged in almost all areas of the economy. The country
with population of some 110 million offers significant domestic market for
locally produced goods and services. The country is also a member of the
Common Market for Eastern and Southern Africa (Comesa) offering huge
benefit of export commodities in preferential tariff rates to a wider
regional market.
The investment sector is a major determinant factor of economic development
for a country like Ethiopia. Both private and government investment is
usually considered as the engine of the economy. Private investment should
be encouraged to increase from year to year and investment constraints
have to be alleviated in order to pave the way for strong economic
development. However, there are investments that could not be undertaken
by privet sector due to its difficult nature, i.e high initial capital and long
gestation period. Such investments, such as major infrastructural work, have
to be spearheaded by the public sector, albeit with close collaboration with
the private sector.
However, the passed command economy system and the lack of experience
between both sides have made it so hard for a private sector to flourish in
Ethiopia.
But now-a-days, as Ethiopia follows free market economy, the role of private
sector is considered key for the achievement of the government’s economy
policy. Accordingly, the Federal Democratic Government of Ethiopia is
encouraging investors to invest their resources to contribute to the
development of the country in all sectors by avoiding all barriers and
facilitating all the menaces for investment.
By taking this encouraging as an opportunity, the promoter of the project
plans to establish Gypsum powder in Girar Jarso Woreda for the benefit of
the promoter, the district community, as well as the country as a whole.
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Project Proposal on Gypsum Powered Manufacturing Project
gypsum powder, which consists of the core of the board and covering of the
core of the board and covering paper. It is widely used as construction
materials mainly for interior finishing like partition, walls, ceiling and
acoustic boards. Major raw materials are gypsum and hard board papers. The
plant can be categorizes as small-scale industry The raw material gypsum is
sorted and washed with water for removal of sand and other impurities. The
lumps thus obtained are then dried and powdered in pulverizer. The dried
gypsum powder is calcined in rotary drum- calcined using light diesel oil as
fuel. The low-pressure burner is used for calcination at a temperature of
160ºC to 180ºC. The process of calcination is done over a period of about 2
hours, so that one and half molecules of water is removed to convert the
gypsum (CaSo4 2 H2O) into plaster of Paris (CaSo4 ½ H2O). After cooling the
product (plaster of Paris) is further pulverised to a fineness of 150 meshes and
packed in airtight polythene lined gunny bags to avoid the plaster of Paris
from absorption of moisture. For manufacture of surgical grade plaster of
Paris, a mineral silinite, which is considered to be a purer variety of gypsum,
is used.
Most Popular Uses of Gypsum Powder
Gypsum powder (hydrous calcium sulfate) is a smooth white powder which is
created by heating of gypsum stone. The gypsum that is mined is heat dried,
crushed and processed to become a powder. The powder is made use of in
different agricultural, construction and industrial applications.
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Project Proposal on Gypsum Powered Manufacturing Project
Fertilizer
Fertilizer which is based on Gypsum powder effectively makes loose the hard
layers of clay and hard subsoil in the garden. It enters into the clay matrix
and makes its structure loose. It enhances the soil composition, facilitates
root growth, air and water movement and prevents soil erosion and water
run-off. It converts salty soil into neutral soil, controls dust erosion and
reduces bulk compactness of tough soil. It prevents water logging by
improving the drainage capability of soil and makes magnesium harmless.
Dry Walls
Dry wall is created with Gypsum powder. This powder is headed to evaporate
major part of its water content and carbon dioxide composition to form
Calcium Sulfate Hemi-hydrate, or Plaster of Paris. Plaster of Paris reconverts
back to calcium sulfate di-hydrate, when combined with water.
This slurry is poured in between two thick sheets of heavy paper which is
flattened and set apart to form drywall. The resulting dry wall boards are
dried further, cut, finished and packed for sale. The dry wall made of Gypsum
is thermal resistant, fire resistant and provides sound insulation. It is durable
and easy to repair. Dry wall can easily adopt many finishes, such as wall
paper, paint and texturing. The dry wall is used for ceilings and interior wall
finishes. As such there is great demand for gypsum powder manufacturers in
Delhi.
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Project Proposal on Gypsum Powered Manufacturing Project
free of odor. As such, many features of exterior and interior construction are
dominated by gypsum products
The project will also provide access to input and output markets for
smallholder market that work with the firm. All these supports will be
extended under the conviction that the fruit of growth induced by the firm
should be trickle down to the larger community.
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Project Proposal on Gypsum Powered Manufacturing Project
Vision:
To become a very successful businessman by providing dependable, quality
production, which can play a great role in filling the market gap and
satisfying customers at Addis Ababa and all the country.
Mission
Objectives are the goals toward which activities of the business are directed
and one of the most important functions the business owner must perform is
setting objectives. This important aims of this sole proprietorship business
among others include the following highly interrelated general goals with each
other.
To create employment opportunities for 99 permanent workers
To become economically self-sufficient in the first year
Become known as trustworthy quality wheat flour products like
Gypsum, Board Powder and Calk supplier in Addis Ababa & its
environs
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Project Proposal on Gypsum Powered Manufacturing Project
3.2. Demographics
The 2007 national census reported a total population for this woreda of
67,312, of whom 34,467 were men and 32,845 were women; none of its
population were urban dwellers. The majority of the inhabitants said they
practised Ethiopian Orthodox Christianity, with 99.81% of the population
reporting they observed this belief
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Project Proposal on Gypsum Powered Manufacturing Project
4. MARKET STUDY
The local demand for gypsum board was met only through import in the
past. However, recently a gypsum board manufacturing plant named
GH Industrial Plc has become operational. However, there is no available
data which indicates the production level of the new plant. Therefore, for
estimating the demand for the product the unsatisfied demand i.e. the
demand which is met through import is considered. Accordingly, the
quantity of gypsum board imported during the period 2002-2011 is given in
Table 3.1
Year Import
2002 28,247
2003 11,901
2004 25,275
2005 54,998
2006 101,379
2007 236,634
2008 105,045
2009 281,953
2010 217,294
2011 380,323
Source: - Ethiopian Revenues & Customs
Authority.
As could be observed from Table 3.1, import of gypsum board exhibits a
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Project Proposal on Gypsum Powered Manufacturing Project
substantial growth especially during the recent six years i.e. 2006--2011.
2
The average annual import, which was30,105 m during the period 2002-
2
2005, has increased by more than seven fold to an average of 220,438 m
during the period 2006-2011.For estimating the present unsatisfied demand
for gypsum board, a growth rate 13% which is equivalent to growth rate of
the contribution of the construction sector to GDP during the period 2001--
2010 is considered.
The demand for gypsum board is directly related with the growth in the
construction sector in general and the housing construction sub sector in
particular which in turn depends on the overall economic development of
the country.
The contribution of the construction sector to the GDP during the period
2001 – 2010 have been growing at annual average growth rate of 13
percent which is above the average annual growth rate of real GDP
during the period under consideration (11.4 %), indicating a rise in the
share of the construction sector within the overall economy.
According to the GTP, during the period 2010/11 – 2014/15 the real GDP
of the country (at a base case scenario) is expected to grow at an average
annual growth rate of 11.2%. Moreover, during the same period the
annual average planned targets of growth for the construction sector is
20%.
Accordingly, by considering the above factors the demand for gypsum board
is conservatively assumed to grow at a rate of 10%. Accordingly,
projected unsatisfied demand is presented inTable 3.2.
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Project Proposal on Gypsum Powered Manufacturing Project
Projected
Year Demand
2013 472,741
2014 520,015
2015 572,017
2016 629,219
2017 692,140
2018 761,354
2019 837,490
2020 921,239
2021 1,013,363
2022 1,114,699
4.3. Pricing and Distribution
The current factory price of Gypsum powder is between 125 and 160 birr
per bag(25kg) and chalk is 50 birr per box950 pcs) the detail as follows
S/N Raw materials unit Unit price
1 Gypsum powder for wall check 25kg bag 160
2 Gypsum powder for Design 25kg bag 125
3 Chalk 50 pcs box 50
Plant Capacity: Based on the market study on the one hand and
considering the minimum economic scale of production on the other, the
envisaged plant will have a production capacity of Based on the market
study and the economic scale of Gypsum powder, and Chalk is 145,000
(25kg bag) and 10,000 box respectively
Production Program: Allotting enough time, during the initial stage, for
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Project Proposal on Gypsum Powered Manufacturing Project
market penetration and technical skill development, the plant will start
production at 80% of its rated capacity which will grow to 90% in the
second year. Full capacity production will be achieved in the third year and
then after. Details of annual production program are shown in Table 4.3.
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Project Proposal on Gypsum Powered Manufacturing Project
5. TECHNICAL ANALYSIS
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Project Proposal on Gypsum Powered Manufacturing Project
Technology Advantages
Currently, Clirik HGM or MTM Grinding milling machinery is the mainstream
equipment’s in gypsum powder production lines, and the powder size meet
most of our customer’s requirement very well. By using these two gypsum
Grinding mills, customers can find these advantages as followings.
1. The machinery use bevel gear transmission, the power is steady.
2. Special internal thin oil lubrication system ensures good lubrication,
efficiently prevent emission problems.
3. The curved air flue can efficiently reduce the resistance of airflow.
Meanwhile, the tangential airflow is good for distribute the minerals,
protecting the machine from being blocked.
4. Curved surface shovel with exchangeable blade, in this way, the running
cost is cut
The plant will use gypsum powder as its main raw material for the production
of
Gypsum Board. Other Chemical additives will also be needed for making the
product. An auxiliary material for packing purpose, made in paper pulps, will
be needed with the brand name of the company. The above mentioned raw
materials will be supplied from the sister company of the gypsum quarry site
in Oromia Region, and the other chemicals will be imported from abroad. The
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Project Proposal on Gypsum Powered Manufacturing Project
gypsum raw material required for the production gypsum board is estimated
at Birr 1,400,000.00 annually
The major auxiliary materials required for the envisaged plant are packing
materials which comprise carton box, printed polypropylene film, scotch tape,
25 kg polypropylene bag, and sewing thread for bags. The annual
requirement for the auxiliary packaging materials at full capacity production
and cost is given in Table 5.2.
B. UTILITIES
The major utilities required for the plant include electric power, water for
general purpose, fuel oil and diesel oil for the process, and fuel and
lubricants for plant machinery and equipment. The total annual
requirement for utilities at full capacity production and the estimated
costs are shown in
The overall land require for the project is 3500 square meters. Land lease cost
is calculated the current rate of Oromia land and investment bureau and the
promoter/investor paid 5% in advance for land approval and construction
purpose and the remaining amount will be paid within 40 years per year .
Land use plan of the project
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Project Proposal on Gypsum Powered Manufacturing Project
The project will seriously involve itself protecting conserving and developing
the natural and flora of the project area in line with the millennium
development goal. To this to will play a vital role in participating the varies
organization and the community around the project area to from an
environmental commute in charge of all environmental issues to be handled
in accordance to varies environmental and water policies of 97/99.
The owner of the project believes to undertake several environmental issues
for the conservation development and creation of sustainable environmental
around the project area.
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Project Proposal on Gypsum Powered Manufacturing Project
CEO
Production
Manager
Secretary
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Project Proposal on Gypsum Powered Manufacturing Project
The promoter is a business man person who has a long year experience in
managing business activities. Therefore, the extensive experience he has
enables him to organize and properly manage the envisaged project
For smooth and efficient operation of the organization, it has been anticipated
that each units will have adequate number of qualified and experienced
manpower. The project G/manager will hire qualified and experienced in
management whose main responsibility is to coordinate the overall activity of
the project.
The distinct units have their own operational teams under them. To fill in all
these work units with the required manpower the project needs 99 permanent
employees out of this 59 are skilled and 40 are unskilled employee, and 150
casual workers are participate the project For smooth operation of the project,
employees will be given on job training, clear duties and responsibilities
under the direct supervision of their respective units.
00.00 ,000.00
2,0 24
13 Store keeper Diploma in Accounting 1
00.00 ,000.00
3,0 72
14 Shift leader diploma 2
00.00 ,000.00
Diploma in Mechanical 5,0 120
15 Mechanic 2
Engineering 00.00 ,000.00
Diploma in Electrical 120
16 Electrician 2
Engineering 5,000.00 ,000.00
720
18 Production worker 8th Grade or above 40
1,500.00 ,000.00
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19 Cleaner 2
8th Grade 1,000.00 ,000.00
48
20 Driver 2
12 complete 2,000.00 ,000.00
48
21 Guard 4
8th Grade or above 1,000.00 ,000.00
total
70 2,244,000.00
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Project Proposal on Gypsum Powered Manufacturing Project
7. FINANCIAL STUDY
7.1. General
The cost of the project is classified as fixed incitement cost and initial working
capital. With regards to fixed investment cost of the project, the land lease,
building and civil works cost, machinery and equipment cost office furniture
costs and fuel costs will be required. As to working and operating cost a brief
illustration will be given as to utilities, salary expense, maintenance cost and
depreciation cost and the other related costs
7.2.1. Fixed costs
This include the land development, building and civil works cost, machinery
and equipment cost office furniture costs.
Table 7.1: land development
S/N Description Estimated cost
1 land Cleaning and leaving 700,000
2 Cannel work 400,000
Total 1,100,000
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Project Proposal on Gypsum Powered Manufacturing Project
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Project Proposal on Gypsum Powered Manufacturing Project
7.3.2. Financing
The total investment capital of the project is to be financed from the
promoter’s equity and bank loan. Out of the total capital birr 7,911,945
(30%) is contributed by the promoter while the remaining balance of birr
18,461,205 (70%) is to be financed by local banks. The bank loan will be
repaid based on the following terms and conditions:
Loan amount = birr 18,461,205
Installment period/ term = 10 years
Interest on loan (including service charge) = 12.5%
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Project Proposal on Gypsum Powered Manufacturing Project
Year
Principal Interest
Year ending
Repayment Payment Balance
0 - - 18,461,205
1 1,846,121 2,307,651 16,615,085
2 1,846,121 2,076,886 14,768,964
3 1,846,121 1,846,121 12,922,844
4 1,846,121 1,615,355 11,076,723
5 1,846,121 1,384,590 9,230,603
6 1,846,121 1,153,825 7,384,482
7 1,846,121 923,060 5,538,362
8 1,846,121 692,295 3,692,241
9 1,846,121 461,530 1,846,121
10 1,846,121 230,765 0
0
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Project Proposal on Gypsum Powered Manufacturing Project
1.3
Packaging 1,650,000 1,732,500 1,819,125 1,910,081 2,005,585 2,105,865 2,211,158 2,321,716 2,437,801 2,559,692
materials
7,391,000 6,028,050 6,329,453 6,645,925 6,978,221 7,327,132 7,693,489 8,078,164 8,482,072 8,906,175
2 Administrative costs
2.1 Salary and wage 2,244,000 2,356,200 2,474,010 2,597,711 2,727,596 2,863,976 3,007,175 3,157,533 3,315,410 3,481,181
2.2 Employee benefits 561,000 589,050 618,503 649,428 681,899 715,994 751,794 789,383 828,853 870,295
2.3
Repair and 395,000 414,750 435,488 457,262 480,125 504,131 529,338 555,805 583,595 612,775
maintenance
2.4 Insurance 197,500 207,375 217,744 228,631 240,062 252,066 264,669 277,902 291,797 306,387
2.5 utilities 100,000 105,000 110,250 115,763 121,551 127,628 134,010 140,710 147,746 155,133
2.6 Office supplies 80,000 84,000 88,200 92,610 97,241 102,103 107,208 112,568 118,196 124,106
2.7
Miscellaneous 77,800 81,690 85,775 90,063 94,566 99,295 104,259 109,472 114,946 120,693
expense
Sub total 3,655,300 3,838,065 4,029,968 4,231,467 4,443,040 4,665,192 4,898,452 5,143,374 5,400,543 5,670,570
Total cost working capital 11,046,300 9,866,115 10,359,421 10,877,392 11,421,261 11,992,324 12,591,941 13,221,538 13,882,615 14,576,745
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Project Proposal on Gypsum Powered Manufacturing Project
The project will collect its revenue from the provision of Gypsum, Phoenix
Powder , Chalk. The selling of intended output has estimated based on the
current market price of similar service provision in district as well as country.
The annual sale program is formulated based on proposed plant capacity
considered the problem of market penetration and skill development of
production at the initial stage of the production period.
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Project Proposal on Gypsum Powered Manufacturing Project
Financial statementsProjected
Profit/loss statementMR. SHIMELES SEMEANEH
Gypsum Powder Production Factory
Projected profit/loss statement
In ' birr
Project Year
Description 1 2 3 4 5 6 7 8 9 10
Gross Sales 21,250,000 22,312,500 23,428,125 24,599,531 25,829,508 27,120,983 28,477,032 29,900,884 31,395,928 32,965,725
Less: Production
11,046,300 11,598,615 12,178,546 12,787,473 13,426,847 14,098,189 14,803,098 15,543,253 16,320,416 17,136,437
costs
Gross profit 10,203,700 10,713,885 11,249,579 11,812,058 12,402,661 13,022,794 13,673,934 14,357,631 15,075,512 15,829,288
Less: Interest on loan 2,307,651 2,423,033 2,544,185 2,671,394 2,804,964 2,945,212 3,092,473 3,247,096 3,409,451 3,579,924
Less: Depreciation 1,230,000 1,291,500 1,356,075 1,423,879 1,495,073 1,569,826 1,648,318 1,730,734 1,817,270 1,908,134
Profit before tax 6,666,049 6,999,352 7,349,319 7,716,785 8,102,625 8,507,756 8,933,144 9,379,801 9,848,791 10,341,230
Less: Income tax 2,333,11
2,449,773 2,572,262 2,700,875 2,835,919 2,977,715 3,126,600 3,282,930 3,447,077 3,619,431
(35%) 7.28
Net Profit 4,332,932 4,549,579 4,777,058 5,015,911 5,266,706 5,530,041 5,806,543 6,096,871 6,401,714 6,721,800
Note: Sales revenue is assumed to increase by 5% annually
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Project Proposal on Gypsum Powered Manufacturing Project
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Project Proposal on Gypsum Powered Manufacturing Project
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Project Proposal on Gypsum Powered Manufacturing Project
The payback period is the amount of time required for a firm to recover its
initial investment in a project, as calculate from cash inflow
The investment cost and income statement projection are used to project
the pay-back period
= 26,373,150
4,332,932 1,230,000
= 4.74=5Years
The payback period =5 is less than the maximum acceptable payback
period (10) therefore accept the project.
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Project Proposal on Gypsum Powered Manufacturing Project
7.5.3. IRR
The internal rate of the project is the rate of discount that radios the present
value of the investigated project to zero. In calculating the IRR, the discount
rate can be adjusted until the NPV becomes Zero or at least as to zero.
Hence, the IRR of this project is calculated as follows
After tax IRR = 30 + 5 (30.5/48.5 million)
=33.1%
IRR=33.1% of the project returns its initial investment cost within its life
Therefore the project is financially viable with an internal rate of return (IRR)
of 33.1% and net present value (NPV) 57 million birr at discount rate 35%.
8. SENSITIVITY ANALYSIS
The major risk of this project shall be high market price fluctuation and
turnover the skilled and trained man power. These risks can be mitigated.
The high staff turnover may be lessened by creating conductive working
atmosphere and providing some benefits. For this project, 25% benefit is
proposed for the permanent employees
Characteristic (Personal) Risk: This is the most important risk, which
should be seriously considered? As to this company, the promoter have
sufficient years of work experience in both government and private
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Project Proposal on Gypsum Powered Manufacturing Project
Collateral Risk: Since the owners of the project are engaged on different
related business, there is no any risk related to collateral. In this regard, the
proposed building and other proposed equipment and the business as a
whole are dependable securities. The experience and skill of the owner as
well as the manager and the other expertise add confidence to the lenders.
Therefore, there is no risk regarding collateral in general.
All the identified risks, which are related to the universally accepted lending
policy, are to the acceptable level that keeps the lender’s interest in safe
position. Furthermore, the quality of the assets of the company is
dependable and the projected finical reports show that the company will
have a capacity to pay the principal and interest without any problem with
in short period of time.
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Project Proposal on Gypsum Powered Manufacturing Project
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